2004 CHRYSLER VOYAGER brake fluid

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-2
Body Control Module......... 8W-40-2, 3, 4, 5, 6,
7, 8, 9, 11, 12
Brake Fluid Level Switch.............. 8W-40-9
Clockspring........................ 8W-40-10
Controller Antilock Brake.......... 8W-40-10, 14
Engine Control Module.......... 8W-40-8, 10, 14
Engine Coolant Temp Sensor......... 8W-40-7, 8
Engine Oil Pressure Sensor........... 8W-40-14
Engine Oil Pressure Switch........... 8W-40-14
Front Control Module........ 8W-40-9, 10, 13, 14
Fuel Pump Module................... 8W-40-2
Fuse 24............................ 8W-40-2
G200..................... 8W-40-2, 11, 12, 13
G300.............................. 8W-40-9
Instrument Cluster........ 8W-40-2, 3, 4, 5, 6, 7,
8, 9, 11, 12, 13
Integrated Power Module........ 8W-40-2, 7, 8, 9,
10, 13, 14
Left Front Door Ajar Switch............ 8W-40-3
Left Front Door Lock Motor/Ajar Switch . . 8W-40-3Component Page
Left Sliding Door Control Module........ 8W-40-4
Left Sliding Door Latch Sensing Switch . . . 8W-40-4
Left Sliding Door Lock Motor/Ajar Switch . 8W-40-4
Left Speed Control Switch............ 8W-40-10
Liftgate Ajar Switch.................. 8W-40-3
Liftgate Cinch/Release Motor........... 8W-40-3
Message Center.................. 8W-40-6, 13
Multi-Function Switch................ 8W-40-6
Parking Brake Switch............. 8W-40-11, 12
Powertrain Control Module....... 8W-40-7, 10, 14
Right Front Door Ajar Switch........... 8W-40-3
Right Front Door Lock Motor/Ajar
Switch.......................... 8W-40-3
Right Sliding Door Control Module...... 8W-40-5
Right Sliding Door Latch Sensing Switch . . 8W-40-5
Right Sliding Door Lock Motor/Ajar
Switch.......................... 8W-40-5
Right Speed Control Switch........... 8W-40-10
Traction Control Switch............. 8W-40-7, 8
Vehicle Speed Sensor............... 8W-40-7, 8
Washer Fluid Level Switch............. 8W-40-9
RS8W-40 INSTRUMENT CLUSTER8W-40-1

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch............... 8W-80-6
A/C Pressure Sensor.................. 8W-80-6
A/C-Heater Control C1 (MTC).......... 8W-80-6
A/C-Heater Control C2 (MTC).......... 8W-80-7
Accelerator Pedal Position Sensor (Diesel) . 8W-80-7
Adjustable Pedals Module (Except Export) . 8W-80-7
Adjustable Pedals Motor (Except Export) . . 8W-80-8
Adjustable Pedals Relay (Except Export/Except
Memory)......................... 8W-80-8
Adjustable Pedals Sensor (Except Export) . 8W-80-8
Adjustable Pedals Switch (Except Export) . 8W-80-9
Airbag Control Module (ORC) (Base)..... 8W-80-9
Airbag Control Module C1 (ORC)
(Premium)...................... 8W-80-10
Airbag Control Module C2 (ORC)
(Premium)....................... 8W-80-11
Ambient Temperature Sensor.......... 8W-80-11
ATC Remote Sensor (ATC)............ 8W-80-12
Auto Temp Control C1............... 8W-80-12
Auto Temp Control C2............... 8W-80-12
Auto Temp Control C3............... 8W-80-13
Automatic Day/Night Mirror (Luxury) . . . 8W-80-13
Back-Up Lamp Switch (MTX).......... 8W-80-13
Battery Temperature Sensor........... 8W-80-13
Blower Motor Resistor C1 (MTC)....... 8W-80-14
Blower Motor Resistor C2 (MTC)....... 8W-80-14
Body Control Module C1.............. 8W-80-14
Body Control Module C2.............. 8W-80-15
Body Control Module C3.............. 8W-80-16
Body Control Module C4.............. 8W-80-17
Body Control Module C5.............. 8W-80-18
Boost Pressure Sensor (Diesel)......... 8W-80-18
Brake Fluid Level Switch............. 8W-80-19
Brake Lamp Switch................. 8W-80-19
Brake Transmission Shift Interlock
Solenoid........................ 8W-80-19
C100............................. 8W-80-19
C100............................. 8W-80-20
C101 (Diesel)...................... 8W-80-20
C101 (Diesel)...................... 8W-80-21
C101 (Gas)........................ 8W-80-21
C101 (Gas)........................ 8W-80-21
C102 (Gas)........................ 8W-80-21
C102 (Gas)........................ 8W-80-22
C103 (Diesel)...................... 8W-80-22
C103 (Diesel)...................... 8W-80-22
C104 (Except Export)................ 8W-80-23
C104 (Except Export)................ 8W-80-23
C106 (Export)...................... 8W-80-23
C106 (Export)...................... 8W-80-23
C107 (Export)...................... 8W-80-24
C107 (Export)...................... 8W-80-24Component Page
C110 (Gas Export).................. 8W-80-24
C110 (Gas Export).................. 8W-80-24
C111(EATX)....................... 8W-80-25
C111(EATX)....................... 8W-80-25
C112 (Except Export)................ 8W-80-25
C112 (Except Export)................ 8W-80-25
C200............................. 8W-80-26
C200............................. 8W-80-28
C201 (Base ORC)................... 8W-80-30
C201 (Base ORC)................... 8W-80-30
C202............................. 8W-80-30
C202............................. 8W-80-30
C204 (Premium).................... 8W-80-31
C204 (Premium).................... 8W-80-31
C300 (LHD)....................... 8W-80-31
C300 (LHD)....................... 8W-80-32
C300 (RHD)....................... 8W-80-32
C300 (RHD)....................... 8W-80-32
C301 (Except Premium).............. 8W-80-33
C301 (Except Premium).............. 8W-80-33
C301 (LHD Premium/Memory)......... 8W-80-33
C301 (LHD Premium/Memory)......... 8W-80-33
C301 (RHD/LHD Premium Except
Memory)........................ 8W-80-34
C301 (RHD/LHD Premium Except
Memory)........................ 8W-80-34
C302 (Except RHD Memory).......... 8W-80-34
C302 (Except RHD Memory).......... 8W-80-34
C302 (RHD Memory)................ 8W-80-35
C302 (RHD Memory)................ 8W-80-35
C303 (LHD)....................... 8W-80-35
C303 (LHD)....................... 8W-80-36
C303 (RHD)....................... 8W-80-36
C303 (RHD)....................... 8W-80-36
C304 (LHD Premium ORC)........... 8W-80-37
C304 (LHD Premium ORC)........... 8W-80-37
C304 (Base ORC)................... 8W-80-37
C304 (Base ORC)................... 8W-80-37
C305............................. 8W-80-37
C305............................. 8W-80-38
C306 (RHD Premium ORC)........... 8W-80-38
C306 (RHD Premium ORC)........... 8W-80-38
C306 (Base ORC)................... 8W-80-38
C306 (Base ORC)................... 8W-80-39
C307 (Base ORC)................... 8W-80-39
C307 (Base ORC)................... 8W-80-39
C307 (Premium ORC)................ 8W-80-40
C307 (Premium ORC)................ 8W-80-40
C308............................. 8W-80-41
C308............................. 8W-80-41
C309............................. 8W-80-41
C309............................. 8W-80-42
RS8W-80 CONNECTOR PIN-OUTS8W-80-1

BRAKE FLUID LEVEL SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
2 Z420 20BK/OR GROUND
BRAKE LAMP SWITCH - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 A103 18GY/RD FUSED B(+)
2 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
2 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
3 V30 20VT/WT (GAS) S/C BRAKE SWITCH OUTPUT
4 V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE
5 Z429 20BK/OR GROUND
6 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
2 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
C100 - BLACK (BODY SIDE)
CAV CIRCUIT
1 D21 20WT/DG
2 D123 20WT/BR
3 D15 20DG/YL (DIESEL)
3 D20 20WT/LG (GAS)
4 T141 20YL/OR (GAS MTX EXPORT)
5 Z111 20BK/WT
6 N1 16DB/OR (DIESEL)
6 G31 18VT/LG (EXCEPT EXPORT)
7 N2 18DB/YL (DIESEL)
7 D15 20DG/YL (GAS EATX)
8 K22 20OR/DB (DIESEL)
8 V32 20VT/YL (GAS)
9 B29 20DG/WT
10 V37 20VT
11 V30 20VT/WT (GAS)
12 K900 20DB/DG
13 B1 18DG/OR (ANTILOCK BRAKES)
14 B2 18DG/LB (ANTILOCK BRAKES)
RS8W-80 CONNECTOR PIN-OUTS8W-80-19

FRONT CONTROL MODULE - BLACK 49 WAY
CAV CIRCUIT FUNCTION
1 A1 B(+)
2 A1 B(+)
3 L43 LEFT LOW BEAM DRIVER
4 L34 RIGHT HIGH BEAM DRIVER
5 L33 LEFT HIGH BEAM DRIVER
6 L44 RIGHT LOW BEAM DRIVER
7- -
8 Z117, Z118, Z343, Z344 GROUND
9 A1 B(+)
10 FCM 10 HORN RELAY CONTROL
11 FCM 11 NAME BRAND SPEAKER RELAY CONTROL
12 P201 (EXCEPT EXPORT) ADJUSTABLE PEDALS RELAY CONTROL
13 FCM 13 PARK LAMP RELAY CONTROL
14 FCM 14 FRONT WIPER ON/OFF RELAY CONTROL
15 C41 (DIESEL) CABIN HEATER ASSIST CONTROL
16 W7 FRONT WIPER PARK SWITCH SENSE
17 X3 HORN SWITCH SENSE
18 W1 WASHER FLUID LEVEL SWITCH SENSE
19 FCM 19 FUSED IGNITION SWITCH OUTPUT (START)
20 A114 FUSED B(+) (I.O.D.)
21 L78 FUSED PARK LAMP RELAY OUTPUT (RIGHT)
22 D25 PCI BUS
23 G931 (DIESEL) AMBIENT TEMPERATURE SENSOR RETURN
24 - NOT USED
25 G31 (DIESEL) AMBIENT TEMPERATURE SENSOR SIGNAL
26 L13 (EXPORT) HEADLAMP ADJUST SIGNAL
27 F1, F2 FCM OUTPUT (UNLOCK-RUN-START)
28 - NOT USED
29 F100 ORC RUN ONLY DRIVER
30 FCM 30 FRONT/REAR BLOWER MOTOR RELAY CONTROL
31 FCM 31 DEFOGGER RELAY CONTROL
32 FCM 32 (EXPORT) HEADLAMP WASHER RELAY CONTROL
33 FCM 33 FRONT FOG LAMP RELAY CONTROL
34 FCM 34 FRONT WIPER HIGH/LOW RELAY CONTROL
35 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
36 B20 BRAKE FLUID LEVEL SWITCH SENSE
37 F20 FUSED IGNITION SWITCH OUTPUT (RUN-START)
38 A1 B(+) (WHEN IPM C5 CPA IS NOT ENGAGED)
39 T2 (MTX) TRS REVERSE SENSE
40 - NOT USED
41 L77 FUSED PARK LAMP RELAY OUTPUT (LEFT)
42 D123 FLASH PROGRAM ENABLE
43 Z116 GROUND
44 L50 (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
44 L50 (GAS) BRAKE LAMP SWITCH OUTPUT
45 W10 FRONT WASHER PUMP MOTOR CONTROL
46 W20 REAR WASHER PUMP MOTOR CONTROL
47 K32 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
48 F201 ORC RUN-START DRIVER
49 - -
8W - 80 - 74 8W-80 CONNECTOR PIN-OUTSRS

INTEGRATED POWER MODULE C7 - 20 WAY
CAV CIRCUIT FUNCTION
1 C16 20DB/GY FUSED DEFOGGER RELAY OUTPUT
2 T141 20YL/OR (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
2 T751 20YL (GAS) FUSED IGNITION SWITCH OUTPUT (START)
3 D25 20WT/VT PCI BUS
4 L13 20WT/YL (EXPORT) HEADLAMP ADJUST SIGNAL
5 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
6- -
7 W7 20BR/GY WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
9 F201 20PK/OR ORC RUN-START DRIVER
10 - -
11 A106 20LB/RD FUSED B(+)
12 P201 20LG/DB (EXCEPT EXPORT/EX-
CEPT MEMORY)ADJUSTABLE PEDALS RELAY CONTROL
13 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
14 - -
15 A114 16GY/RD FUSED B(+) (I.O.D.)
16 D123 20WT/BR FLASH PROGRAM ENABLE
17 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
17 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
18 X13 16DG/GY (HIGHLINE) NAME BRAND SPEAKER RELAY OUTPUT
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT ORC RUN ONLY DRIVER
INTEGRATED POWER MODULE C8 - ORANGE 10 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
2 N1 18DB/OR (GAS) FUEL PUMP RELAY OUTPUT
3 A108 18LG/RD (EXCEPT EXPORT) FUSED B(+)
3 A108 20LG/RD (EXPORT) FUSED B(+)
3 A108 20LG/RD (EXPORT) FUSED B(+)
4 A103 18GY/RD FUSED B(+)
5 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
6 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
7 C51 12LB/BR (3 ZONE HVAC) FUSED REAR BLOWER MOTOR RELAY OUTPUT
8- -
9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
RS8W-80 CONNECTOR PIN-OUTS8W-80-85

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Sentry Key Remote Entry Module
(Skreem)BK At Steering Column 20, 21, 22, 23, 31
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) Nat Near Overhead Console N/S
Thatcham Alarm Module C1
(United Kingdom)BK Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except
Export)BK Left Quarter Panel N/S
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 18 19
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Right Side of Instrument Panel 20, 24, 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector.
(8) Disconnect the vapor purge vacuum hose from
throttle body.
(9) Disconnect the PCV hose (Fig. 114).
(10) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 115). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(11) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
116).
(12) Remove intake manifold bolts and remove the
manifold (Fig. 117).
(13) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(14) Clean and inspect the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) and (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check manifold for:
²Damage and cracks.
Fig. 113 Intake Manifold Port Repair
1 - BRAKE BOOSTER PORT = 1/49±18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/89±18 NPT PIPE TAP
2 - DRILL BIT = 7/169BRAKE BOOSTER PORT
2 - DRILL BIT = 11/329LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
Fig. 114 PCV & HOSE
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 115 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
9 - 146 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)

REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT(Fig. 10).
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
REMOVAL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 11).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 12).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 13).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 15).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 14).
(24) Remove cradle crossmember from vehicle (Fig.
15).
Fig. 10 FRONT CRADLE CROSSMEMBER CAGED
NUT
1 - BRACKET
2 - CAGED NUT
Fig. 11 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)